Reduced misting oven cleaner

Abstract: Spray-on cleaners that can be delivered by pump or pressurized gas aerosol spray head have been known to cause respiratory distress in the form of a chocking mist. The chocking mist associated with aerosol use can be reduced or eliminated by formulating surface cleaning compositions that can be dispensed through a spray head resulting in an aerosol or mist droplet having a mean particle size greater than about 200 µm. We have found that typical spray-on cleaners have a mean particle size less than about 175 µm and, depending on the concentration and degree of irritation of strong base or strong acid components, can cause severe respiratory distress. Preferred thickeners have been found for use in the non-chocking aerosol or mist compositions.

Description: Field of the Invention The invention relates to aqueous acidic cleaners that are used to remove soils from hard surfaces such as floors and walls. Background of the Invention Acidic and alkaline cleaning compositions for hard surfaces have been used for many years to remove stubborn soils from a variety of surfaces found in household and institutional locations. Such soils include inorganic soils and soils derived from organic sources, such as fats, oils, proteins and carbohydrates, which can form hard tenacious deposits on a variety of surfaces including ceramic, stainless steel, concrete, tile and metal food preparation surfaces. Typical inorganic solids comprise insoluble materials derived from the hardness components of service. water including substantially insoluble salts of calcium, magnesium, iron, manganese, etc. Such inorganic salts can be combined in some cases with organic residues which can form large, difficult to remove soil deposits. These soils can be unsightly, can take the form of large deposits of charred or baked-on residue, or large areas of white insoluble soap scum or hardness deposits. These soils can also promote or support the growth of microorganisms that can under certain circumstances contaminate food or other contaminatable materials or surfaces. A variety of cleaning compositions have been developed to deal with the tenacious organic and organic/inorganic matrix soils common in a variety of surfaces. One particularly useful form of cleaner is an aqueous alkaline cleaner commonly delivered from a pressurized aerosol or pump spray device. These types of cleaners have great utility for a variety of surfaces because the material can be delivered by spray to vertical, overhead or inclined surfaces or to surfaces having a complex curved or convoluted surface while , achieving substantially complete coverage of the surface with the spray-on liquid cleaner. Acid spray-on cleaners are also known for removing basic inorganic soils and are becoming more common. One substantial problem that arises with such spray-on materials relates to an airborne mist or finely divided aerosol generated during the spraying process. The aqueous liquid is converted by the action of propellant or pump action into a spray that is accompanied by a finely divided aerosol or mist. The spray portion contacts and remains on the target surface, while a substantial proportion of the aerosol can remain suspended in the atmosphere. Such aqueous compositions having a strong acid or strong base cleaning component in the form of a finely divided aerosol or mist can cause respiratory distress in the user. Upon breathing the finely divided aerosol or mist, a very strong and irrepressible choking response is seen in most individuals that come in contact with irritating proportions of the aerosol produced by typical spray-on cleaners. The choking response is inconvenient, reduces cleaning efficiency in a variety or applications and in sensitive individuals can cause asthma attacks, respiratory damage, or other discomfort or injury. To alleviate, to some degree, the choking response, some products have been formulated with reduced quantities of the strongly alkaline or strongly acid cleaning components to reduce the choking response. Strong caustic has been replaced by reduced alkalinity bases such as bicarbonate or by solvent materials. The reduction in concentration or substitution of these materials can often reduce the cleaning activity and effectiveness of the material when used. Crotty et al., United States Patent No. 3,644,210, teach an alkaline cleaning material useful for removing burnt-on, baked-on food and grease from cooking surfaces comprising substantial proportions of alkali metal hydroxide in an aqueous cleaning base. Eisen, United States Patent No. 3,779,933, teaches an aqueous alkali metal cleaning composition using clay and organic thickening materials. Mukai et al., United States Patent No. 3,813,343, teach oven cleaning compositions containing an amine or ammonia base combined with dimethyl sulfoxide solvent and other compositions. Wise et al., United States Patent No. 3,829,387, teach caustic cleaning compositions containing substantial proportions of sodium hydroxide, clay thickeners, and solvents in an aqueous base. US-4157921, GB-2193505, CA-1151501, US-4207215, US-4521332, US-4652393, AU-9333710, US-3681141, JP-53046302, GB-1146998 and WO-9219713 all describe alkaline or acidic aqueous sprayable cleaning compositions with a wide variety of ingredients, but none of these publications is related to the problem of the choking response to the particle size of the aerosol. Culshaw, United States Patent No. 4,676,920, teaches a thickened viscous scouring material using surfactants, abrasives and solvents for soil removal. De Buzzaccarini, United States Patent No. 4,767,563, teach liquid scouring cleaning compositions using solvents, abrasives and surfactants for soil removal from hard surfaces. Cockrell, Jr., United States Patent No. 4,877,691 (International Application No. PCT/US91/05092) teaches a composition used to pretreat an oven to promote the subsequent removal of hardened baked-on soils that form on the pretreatment material. Dimond et al., Canadian Patent No. 1,047,903, teach oven cleaning compositions having reduced proportions of sodium hydroxide which are thickened using a bentonite in a substantially aqueous base. Silvester, Canadian Patent No. 1,211,674, teaches an improved oven cleaner using sodium bicarbonate as an alkali, glycerol as a solvent, a clay thickener in an aqueous formulation for oven cleaning. Flannery, United Kingdom Patent No. 2,019,876, teaches an aerosol comprising sodium bicarbonate as an oven cleaner. The prior art taken as a whole shows that skilled artisans in experimenting with improving acid and alkaline hard surface cleaners, in particular alkaline oven cleaners, have attempted to reduce concentrations of sodium hydroxide to reduce the choking response. Ammonia or an organic base has been used to replace sodium hydroxide in reduced alkaline cleaners. Other inorganic materials, such as sodium carbonate or sodium bicarbonate have also been used to replace sodium hydroxide. A variety of glycol, ether or dimethyl sulfoxide solvent material have been used to enhance the detergent properties of the reduced alkaline materials using organic surfactants. The prior art taken as a whole has attempted to replace sodium hydroxide to reduce choking response but does not recognize that the choking properties of these cleaners is related to the particle size of the aerosol. For this reason, no attempt has been made in the prior art to formulate to adjust the particle size of the aerosol to reduce respiratory distress or choking reflex. Brief Description of the Invention We have found that thixotropic aqueous strong acid cleaning compositions that are used in a spray-on format can be made non-choking by producing a formulation that when sprayed results in the creation of an airborne aerosol or mist having a mean particle size greater than 200 µm. The materials of the invention produce little or no small particle aerosol. The concentration of small particle airborne aerosol from a mean particle size greater than 200 µm is not sufficient to cause respiration difficulty. Aerosol sprays, either propellant driven or pump driven, create a spray pattern of the aqueous liquid that contacts the target surface. Some spray nozzles produce a greater proportion of small particle airborne aerosol than others. The major proportion of the liquid resides in large sprayed deposits which contact and remain on a target surface. A small proportion becomes an airborne aerosol or mist. The mist or aerosol particle size, discussed above, relates to the mist created during the spray action and is not directed to the material sprayed which remains in contact with the target surface. Any spray pattern created during spraying operations will contain an array of large and small spray particles which do not become airborne and are transported directly to and remain in place on the treated surface. We are not concerned with the proportion of the spray that remain on the target surface. We are primarily concerned only with the portions of the sprayed material that take the form of a small particle size aerosol or mist that can remain suspended in or transported by the atmosphere for a substantial period of time at least 5 seconds, typically 30 seconds to 10 minutes after spraying. The improved compositions comprise aqueous materials comprising a strong acid an organic surfactant, an organic polymeric thickener, and a variety of other useful optional ingredients. The cleaners can be packaged in pressurized aerosol spray units using commonly available pressure containers, aerosol valves and aerosol propellants. The cleaners can be used in a pump spray format using a pump spray head and a suitable container. The materials are typically applied to hard surfaces containing difficult inorganic, organic, or matrix-blended soils. Such soils include baked-on or carbonized food residues. Other surfaces can contain soils derived from substantially insoluble hardness components of service water. The enhanced cleaning compositions rapidly remove such soils because the cleaners have a unique combination of cleaning ingredients combined with thickeners that can rapidly remove the soils but resist formation of an amount of mist or aerosol during application that can cause respiratory distress. For the purpose of this application, the terms "aerosol" and "mist" refer to airborne dispersions of small particles comprising the cleaning composition that can remain suspended or dispersed in the atmosphere surrounding a cleaning site for at least 5 seconds, more commonly 30 seconds to 10 minutes. We have found in our research that the respiratory distress or involuntary choking response caused by the inhalation of such mist, depending on the irritation capacity of the cleaning components, is inversely proportional to the particle size of the aerosol or mist. We have found that strongly irritating, strongly acidic or basic materials are increasingly irritating as the mean particle size drops below 200 µm and mildly irritating materials tend to become irritating as the mean particle size drops below 170 µm. However, any sprayable composition can be rendered at worse, mildly irritating if the mean particle size of its aerosol or mist created upon spraying is maintained at greater than 200 µm, preferably greater than 210 µm. Detailed Description of the Invention The sprayable thixotropic aqueous cleaning compositions used in the invention comprise a strong acid in combination with an organic surfactant, and an effective organic thickener material in an aqueous composition. The compositions can contain a variety of other optional ingredients recited below. Strong Acid The aqueous cleaning compositions used in the invention contain as a primary cleaning agent an acid composition typically 1 to 20 wt% that can typically be a strong acid or a strong acid combined with a weak acid. For the purposes of this invention, an acid material is a composition that can be added to an aqueous system and result in a pH less than 7. Strong acids that can be used in the aqueous cleaners of the invention include acids which substantially dissociate in an aqueous solution (strong acid) such as hydrochloric acid, sulfuric acid, trichloroacetic acid, trifluoroacetic acid, nitric acid and others. "Weak" organic and inorganic acids can be used in the invention as a component of the acid cleaner. Weak acids are acids in which the first dissociation step of a proton from the acid cation moiety does not proceed essentially to completion when the acid is dissolved in water at ambient temperatures at a concentration within the range useful to form the present cleaning composition. Such inorganic acids are also referred to as weak electrolytes as the term is used in the text book Quantitative Inorganic Analysis, I. M. Koltoff et al., published by McMillan Co., Third Edition, 1952, pp. 34-37. Most common commercially available weak organic and inorganic acids can be used in the invention. Examples of weak organic and inorganic acids include phosphoric acid, sulfamic acid, acetic acid, hydroxy acetic acid, citric acid, benzoic acid, tartaric acid, maleic acid, malic acid, fumaric acid and the like. We have round in certain applications that mixtures of strong acid with weak acid or mixtures of a weak organic acid and a weak inorganic acid with a strong acid can result in surprisingly increased cleaning efficiency. Such acid cleaners tend to be most effective to clean basic organic and inorganic soils. The soil most commonly cleaned using acid cleaners involves the soils resulting from the precipitation of hardness components of service water with cleaning compositions or food soils that can precipitate in the presence of calcium, magnesium, iron, manganese or other hardness components. Such soils include dairy residue, soap scum, saponified fatty acids or other marginally soluble anionic organic species that can form a soil precipitate or matrix when combined and contacted with divalent hardness components of service water. Surfactant The aqueous cleaning compositions used in the invention contain an organic surfactant composition. Anionic, nonionic, cationic or amphoteric surfactants can be used 1 to 20 wt % surfactant may be present. Anionic materials that can be used in the aqueous compositions used in the invention are surfactants containing a large lipophilic moiety and a strong anionic group. Such anionic surfactants contain typically anionic groups selected from the group consisting of sulfonic, sulfuric or phosphoric, phosphonic or carboxylic acid groups which when neutralized will yield sulfonate, sulfate, phosphonate, or carboxylate with a cation thereof preferably being selected from the group consisting of an alkali metal, ammonium, alkanol amine such as sodium, ammonium or triethanol amine. Examples of operative anionic sulfonate or sulfate surfactants include alkylbenzene sulfonates, sodium xylene sulfonates, sodium dodecylbenzene sulfonates, sodium linear tridecylbenzene sulfonates, potassium octyldecylbenzene sulfonates, sodium lauryl sulfate, sodium palmityl sulfate, sodium cocoalkyl sulfate, sodium olefin sulfonate. Nonionic surfactants carry no discrete charge when dissolved in aqueous media. Hydrophilicity of the nonionic is provided by hydrogen bonding with water molecules. Such nonionic surfactants typically comprise molecules containing large segments of a polyoxyethylene group in conjunction with a hydrophobic moiety or a compound comprising a polyoxypropylene and polyoxyethylene segment. Polyoxyethylene surfactants are commonly manufactured through base catalyzed ethoxylation of aliphatic alcohols, alkyl phenols and fatty acids. Polyoxyethylene block copolymers typically comprise molecules having large segments of ethylene oxide coupled with large segments of propylene oxide. These nonionic surfactants are well known for use in this art area. The lipophilic moieties and cationic groups comprising amino or quaternary nitrogen groups can provide surfactant properties to surfactant molecules. As the name implies to cationic surfactants, the hydrophilic moiety of the nitrogen bears a positive charge when dissolved in aqueous media. The soluble surfactant molecule can have its solubility or other surfactant properties enhanced using low molecular weight alkyl groups or hydroxy alkyl groups. Cationic surfactants can be used in the acidic compositions of the invention. One preferred cationic surfactant material is an oxygen containing amine compound such as an amine oxide. The preferred class of cationic surfactants include tertiary amine oxide surfactants. Tertiary amine oxide surfactants typically comprise three alkyl groups attached to an amine oxide (N→O). Commonly the alkyl groups comprise two lower (C 1- 4 ) alkyl groups combined with one higher C 6-24 alkyl groups, or can comprise two higher alkyl groups combined with one lower alkyl group. Further, the lower alkyl groups can comprise alkyl groups substituted with hydrophilic moiety such as hydroxyl, amine groups, carboxylic groups. Preferred amine oxide materials for the invention comprise dimethylcetylamine oxide, dimethyllaurylamine oxide, dimethylmyristylamine oxide, dimethylstearylamine oxide, dimethylcocoamine oxide, dimethyldecylamine oxide, and mixtures thereof. Amphoteric surfactants can be useful in the invention. Amphoteric surfactants contain both an acidic and a basic hydrophilic moiety in the structure. These ionic functions may be any of the ionic or cationic groups that have just been described previously in the sections relating to anionic or cationic surfactants. Briefly, anionic groups include carboxylate, sulfate, sulfonate, phosphonate, while the cationic groups typically comprise compounds having amine nitrogens. Many amphoteric surfactants also contain ether oxides or hydroxyl groups that strengthen their hydrophilic tendency. Preferred amphoteric surfactants of this invention comprise surfactants that have a cationic amino group combined with an anionic carboxylate or sulfonate group. Examples of useful amphoteric surfactants include the sulfobetaines, N-coco-3,3-aminopropionic acid and its sodium salt, n-tallow-3-amino-dipropionate disodium salt, 1,1-bis (carboxymethyl) -2-undecyl-2-imidazoiinium hydroxide disodium salt, cocoaminobutyric acid, cocoaminopropionic acid, cocoamidocarboxy glycinate, cocobetaine. Preferred amphoteric surfactants for use in the compositions include cocoamidopropylbetaine and cocoaminoethylbetaine. Agueous Compatible Solvents The cleaner materials used in the invention can contain a compatible solvent. Suitable solvents are soluble in the aqueous cleaning composition of the invention at use proportions. Preferred soluble solvents include lower alkanols, lower alkyl ethers, and lower alkyl glycol ethers. These materials are colorless liquids with mild pleasant odors, are excellent solvents and coupling agents and are typically miscible with aqueous cleaning compositions used in the invention. Examples of such useful solvents include methanol, ethanol, propanol, isopropanol and butanol, isobutanol, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, mixed ethylene-propylene glycol ethers. The glycol ethers include lower alkyl (C 1-6 alkyl) ethers including propylene glycol methyl ether, propylene glycol ethyl ether, propylene glycol propyl ether, dipropylene glycol methyl ether, dipropylene glycol ethyl ether, tripropylene glycol methyl ether, ethylene glycol methyl ether, ethylene glycol ethyl ether, ethylene glycol butyl ether, diethylene glycol methyl ether, diethylene glycol butyl ether, ethylene glycol dimethyl ether, ethylene glycol monobutyl ether, and others. The solvent capacity of the cleaners can be augmented by using monoalkanol amines. Thickeners or Viscosity Modifiers The compositions used in the invention require the presence of a material that will provide a composition that is thixotropic, in other words the material when left undisturbed (in a shear mode), retains a high viscosity. However, when sheared, the viscosity of the material is substantially but reversibly reduced. After the shear action is removed, the viscosity returns. These properties permit the application of the material through a spray head. When sprayed from an aerosol container using a propellant, the material undergoes shear as it is drawn up a feed tube into a aerosol spray head under the influence of the pressure of a propellant or is sheared by the action of a pump in a pump action sprayer. In either case, the viscosity must drop to a point such that substantial quantities of the material can be applied using the spray devices used to apply the material to a soiled surface. However, once the material comes to rest on a soiled surface, the materials should regain high viscosity to ensure that the material remains in place on the soil. Preferably, the material can be applied to a surface resulting in a substantial coating of the material that provides the cleaning components in sufficient concentration to result in lifting and removal of the hardened or baked-on soil. While in contact with the soil on vertical or inclined surfaces, the thickeners in conjunction with the other components of the cleaner prevent dripping, slumping or other movement of the material under the effects of gravity. The material should be formulated such that the viscosity of the material is adequate to maintain contact between substantial quantities of the film of the material with the soil for at least a minute, preferably five minutes or more. A variety of well known organic thickener materials are known in the art. Preferred thickeners for use in this invention are natural polymers or gums derived from plant or animal sources. Such materials are often large polysaccharide molecules having substantial thickening capacity. A substantially soluble organic thickener, such as an organic polymer thickener, is used to provide thixotropy to the compositions of the invention. This organic thickener typically comprises 0.01 to 5 wt% polymeric organic thickener, preferably 0.01 to 10 wt% of a polyvinyl alcohol thickener composition for acidic compositions. The preferred thickeners have some substantial proportion of water solubility to promote easy removability. Examples of soluble organic polymer thickeners for the aqueous compositions comprise carboxylated vinyl polymers such as polyacrylic acids and sodium salts thereof, ethoxylated cellulose, hydroxyethyl styrylamide, polyacrylamide thickeners, xanthan compositions, sodium alginate and algin products, hydroxypropyl cellulose, hydroxyethyl cellulose, and other similar aqueous thickeners that have some substantial proportion of water solubility. Compositions used in the invention can be made with small concentrations of xanthan thickeners yet remain substantially water soluble or dispersible using aqueous cleaners or mild aqueous detergent compositions. The preferred thickeners for acid compositions comprise polyvinyl alcohol thickeners having a molecular weight greater than 20,000. The polyvinyl alcohol preferably has a degree of hydrolysis (mole-% of acetate removal from the -OH function) of greater than 87%, and is most preferably fully hydrolyzed (greater than 98.5 mol% acetate removal from the -OH function). Xanthan is an extracellular polysaccharide of xanthomonas campestras. Xanthan is made by fermentation based on corn sugar or other corn sweetener by-products. Xanthan comprises a poly beta-(1→4) -D-Glucopyranosyl backbone chain, similar to that found in cellulose. Aqueous dispersions of xanthan gum and its derivatives exhibit novel and remarkable theological properties. Low concentrations of the gum have relatively high viscosity which permit it economical use and application. Xanthan gum solutions exhibit high pseudoplasticity, i.e. over a wide range of concentrations, rapid shear thinning occurs that is generally understood to be instantaneously reversible. Non-sheared materials have viscosity that appears to be independent of the pH and independent of temperature over wide ranges. Preferred xanthan materials include crosslinked xanthan materials. Xanthan polymers can be crosslinked with a variety of known covalent reacting crosslinking agents reactive with the hydroxyl functionality of large polysaccharide molecules and can also be crosslinked using divalent, trivalent or polyvalent metal ions. Suitable crosslinking agents for xanthan materials include metal cations such as Al-3, Fe+3, Sb+3, Zr+4 and other transition metals, etc. Known organic crosslinking agents can also be used. The preferred crosslinked xanthan agent of the invention is KELZAN AR, a product of Kelco, a division of Merck Incorporated. KELZAN AR is a crosslinked xanthan that provides a thixotropic cleaner that can produce large particle size mist or aerosol when sprayed. Sequestrant The thickened materials used in the invention can contain an organic or inorganic sequestrant or mixtures of sequestrants. Organic sequestrants such as citric acid, the alkali metal salts of nitrilotriacetic acid (NTA), EDTA, alkali metal gluconates, polyelectrolytes such as a polyacrylic acid, can be used herein. The most preferred sequestrants are organic sequestrants such as sodium gluconate due to the compatibility of the sequestrant with the formulation base. The present used thickened cleaning materials can also comprise an effective amount of a water-soluble organic phosphonic acid which has sequestering properties. Preferred phosphonic acids include low molecular weight compounds containing at least two anion-forming groups, at least one of which is a phosphonic acid group. Such useful phosphonic acids include mono-, di-, tri- and tetra-phosphonic acids which can also contain groups capable of forming anions under alkaline conditions such as carboxy, hydroxy, thio and the like. Among these are phosphonic acids having the formulae: R 1 N[CH 2 PO 3 H 2 ] 2 or R 2 C(PO 3 H 2 ) 2 OH, wherein R 1 may be -[(lower) alkylene]N[CH 2 PO 3 H 2 ] 2 or a third CH 2 PO 3 H 2 moiety; and wherein R 2 is selected from the group consisting of C 1 C 6 alkyl. The phosphonic acid may also comprise a low molecular weight phosphonopolycarboxylic acid such as one having about 2-4 carboxylic acid moieties and about 1-3 phosphonic acid groups. Such acids include 1-phosphono-1- methylsuccinc acid, phosphonosuccinic acid and 2-phosphonobutane-1,2,4-tricarboxylic acid. Other organic phosphonic acids include 1-hydroxyethylidene-1,1-diphosphonic acid (CH 3 C(PO 3 H 2 ) 2 OH), available from Monsanto Industrial Chemicals Co., St. Louis, MO as Dequest® 2010, a 58-62% aqueous solution; amino [tri (methylenephosphonic acid)] (N[CH 2 PO 3 H 2 ] 3 ), available from Monsanto as Dequest® 2000, a 50% aqueous solution; ethylenediamine [tetra(methylene-phosphonic acid)] available from Monsanto as Dequest® 2041, a 90% solid acid product; and 2-phosphonobutane-1,2,4-tricarboxylic acid available from Mobay Chemical Corporation, Inorganic Chemicals Division, Pittsburgh, PA as Bayhibit AM, a 45-50% aqueous solution. It will be appreciated that, the above-mentioned phosphonic acids can also be used in the form of water-soluble acid salts, particularly the alkali metal salts, such as sodium or potassium; the ammonium salts or the alkylol amine salts where the alkylol has 2 to 3 carbon atoms, such as mono-, di-, or tri- ethanolamine salts. If desired, mixtures of the individual phosphonic acids or their acid salts can also be used. Further useful phosphonic acids are disclosed in U.S. Patent No. 4,051,058, The present compositions can also incorporate a water soluble acrylic polymer which can act to condition the wash solutions under end-use conditions. Such polymers include polyacrylic acid, polymethacrylic acid, acrylic acid-methacrylic acid copolymers, hydrolyzed polyacrylamide, hydrolyzed polymethacrylamide, hydrolyzed acrylamidemethacrylamide copolymers, hydrolyzed polyacrylonitrile, hydrolyzed polymethacrylonitrile, hydrolyzed acrylonitrilemethacrylonitrile copolymers, or mixtures thereof. Water-soluble salts or partial salts of these polymers such as the respective alkali metal (e.g. sodium or potassium) or ammonium salts can also be used. The weight average molecular weight of the polymers is from 500 to 15,000 and is preferably within the range of from 750 to 10,000. Preferred polymers include polyacrylic acid, the partial sodium salt of polyacrylic acid or sodium polyacrylate having weight average molecular weights within the range of 1,000 to 6,000. These polymers are commercially available, and methods for their preparation are well-known in the art. For example, commercially-available waterconditioning polyacrylate solutions useful in the present cleaning solutions include the sodium polyacrylate solution, Colloid® 207 (Colloids, Inc., Newark, NJ); the polyacrylic acid solution, Aquatreat® AR-602-A (Alco Chemical Corp., Chattanooga, TN); the polyacrylic acid solutions (50-65% solids) and the sodium polyacrylate powders (m.w. 2,100 and 6,000) and solutions (45% solids) available as the Goodrite® K-700 series from B.F. Goodrich Co.; and the sodium- or partial sodium salts of polyacrylic acid solutions (m.w. 1000-4500) available as the Acrysol® series from Rohm and Haas. The present used composition can also incorporate sequestrants to include materials such as, complex phosphate sequestrants, including sodium tripolyphosphate, sodium hexametaphosphate, and the like, as well as mixtures thereof. Phosphates, the sodium condensed phosphate hardness sequestering agent component functions as a water softener, a cleaner, and a detergent builder. Alkali metal (M) linear and cyclic condensed phosphates commonly have a M 2 O:P 2 O 5 mole ratio of about 1:1 to 2:1 and greater. Typical polyphosphates of this kind are the preferred sodium tripolyphosphate, sodium hexametaphosphate, sodium metaphosphate as well as corresponding potassium salts of these phosphates and mixtures thereof. The particle size of the phosphate is not critical, and any finely divided or granular commercially available product can be employed. Sodium tripolyphosphate is a preferred inorganic hardness sequestering agent for reasons of its ease of availability, low cost, and high cleaning power. Sodium tripolyphosphate acts to sequester calcium and/or magnesium cations, providing water softening properties. It contributes to the removal of soil from hard surfaces and keeps soil in suspension. It has little corrosive action on common surface materials and is low in cost compared to other water conditioners. Sodium tripolyphosphate has relatively low solubility in water (about 14 wt%) and its concentration must be increased using means other than solubility. Typical examples of such phosphates being alkaline condensed phosphates (i.e. polyphosphates) such as sodium or potassium pyrophosphate, sodium or potassium tripolyphosphate, sodium or potassium hexametaphosphate, etc. Metal Protector The compositions used in the invention can contain a material that can protect ferrous metal from corrosion. Such metal protectors include for example sodium gluconate and sodium glucoheptonate. The corrosion inhibitor can comprise 0.01 to 5 wt% of the composition. In addition to the recited components of the compositions of the invention there may also be present adjuvant materials for hard surface cleaning. Such adjuvant materials may include foam enhancing agents, foam suppressing agents (when desired), preservatives, antioxidants, pH adjusting agents, perfumes, colorants, or pacifying or pearlescent agents, builder salts, cosolvents and other useful well understood material adjuvants. The materials used in the invention are commonly applied to soiled surfaces using a pressurized aerosol or aerosol pump spray. In pressurized aerosol application, the compositions are combined with a aerosol propellant and packaged in a metal high pressure container. Typical propellants include lower alkanes such as propane, butane, nitrous oxide, carbon dioxide, and a variety of fluorocarbons. Pressurized aerosol containers typically include a spray head, valve and dip tube that reaches to the opposite end of the container to ensure that the entire contents of the container is dispensed through the action of the propellant. When the valve is opened (depressed), the propellant pressure forces liquid into the dip tube and through the aerosol spray head. At the spray head exit, a spray pattern is created by the geometry of the aerosol valve which directs the material onto the soiled surface. Aerosol containers, dip tubes, propellants and spray valves are well understood commercial technology. Pump spray devices commonly comprise a container spray head valve pump and dip tube. Actuating the pump causes a piston to travel in a cylinder filled with compositions of the invention. The piston motion forces the composition through an aerosol valve causing the spray to adhere to a soiled surface. Once the piston reaches its full travel path, the piston is returned by a spring action to its original position causing the cylinder to fill with additional quantities of the spray material through a valve opening. As the piston is again pressed through the cylinder the valve closes preventing the exit of any of the solution from the cylinder. The pump spray can deliver substantial quantities of the material onto the soiled surface. The materials of the invention can be made by combining the ingredients in an aqueous diluent using commonly available containers and blending apparatus. A preferred method for performing the composition of the invention includes introducing into a stirred production vessel, a quantity of the deionized water followed by the organic thickener material used to provide thixotropic properties to the compositions of the invention. After the thickener is fully solubilized, the other ingredients of the invention can be added in any order. The following examples, experiments and data provide a basis for understanding the nature of the invention and include a best mode. Experimental A. Cleaning Capacity The following preparation was tested for cleaning using a hood and grill soil test or a Crisco test. Hood and Grill Soil Test This test is meant to simulate a cleaner's ability to remove polymerized oils from institutional hoods, ovens, and grills. A 2.5 gram sample of Mazola brand corn oil is spread evenly onto a 35.5 cm by 35.5 cm (14 inch by 14 inch) sheet of stainless steel. The sheet is heated at 200°C for three hours. The heating procedure causes the oil to polymerize to a tenacious varnish-like yellow film. A composition's cleaning ability is measured relative to a standard formulation. One gram samples of the test formulation and the standard are placed onto the polymerized film using a dropper. This is done at room temperature. The time required for the compositions to cause the film to loosen is recorded. By loosen is meant that the film wrinkles and lifts from the stainless steel surface to the point where it is removed by running tap water over the sheet. Crisco Test This test is meant to simulate a cleaner's ability to remove freshly deposited, non-polymerized oils and greases from hard surfaces found in institutional kitchens. A one gram sample of Crisco brand allvegetable shortening is spread evenly onto a 25.5 cm by 25.5 cm (10 inch by 10 inch) glass door of a laboratory hood. A composition's cleaning ability is measured relative to a standard formulation. A test formulation is sprayed onto the soil through an Affa Sprayer No. 5910BA. Five sprays are used in a "domino" pattern. After the fifth spray, the composition is allowed to remain in contact with the soil for one minute before wiping. A Scott brand laboratory Soft Cote Wipe is used to wipe off the soil. Following the wipe, one additional spray is applied to the surface and a new wipe is used to, again, wipe the surface. The efficacy of the cleaner is measured during the one minute after the initial spray and after each wiping. A satisfactory test formulation emulsifies and lifts the soil during the one minute, and leaves a grease free surface after wiping. In particular, the surface should be clean and streak free after the second wipe. Particle Size Analysis and Surface Tension Results - Acid Formulas Examples A-D The acidic formulations evaluated are as follows: Ingredient Weight Percent Formula A B C D Water to 100% to 100% to 100% to 100% Polyvinyl alcohol(PVA) (high molecular weight fully hydrolyzed 350) 0.3 0.5 0.3 - Phosphoric acid (75%) 11.625 11.625 11.625 11.625 Citric acid (50%) 4.875 4.875 4.875 4.875 Butyl carbitol 4.000 4.000 4.000 4.000 Nonyl phenol ethoxylate (9.5 mole) 1.000 1.000 - 1.000 C 12-14 dimethyl amine oxide (30%) 3.500 3.500 - 3.500 Test results are as follows: Formula Tension Irritation Rating Median Particle Micrometers Surface Dvnes/cm A 0 259.9 32.3 B 0 250.3 32.3 C 3 126.9 34.6 D 3 165.1 32.1 The level of irritation for the complete formulas (A and B) made with 0.3 and 0.5% PVA is rated as zero. Again this rating correlates with particle size and not surface tension. The particle size results obtained with formula C indicates that it is the combination of surfactant and PVA that increases the mean particle size. The data above suggest that with mean particle sizes above 200 micrometers that the irritating mist is greatly reduced. All of the data above were with concentrated formulas that are known to be quite irritating. We have demonstrated that the cleaning compositions of the invention which include a highly acid material as an active cleaning component in conjunction with other cleaning ingredients in a thickened aqueous material provides excellent soil removal properties. We have further shown that the irritating effects of mists or aerosols generated using the compositions of the invention in a spray device, can be substantially removed if the material sprayed results in a median particle size that is greater than 200 µm. The thickened materials of the invention do not lose any cleaning capacity once formulated to produce a low particle size aerosol or mist. Example C (absence of surfactant) has been included for comparative purposes. The invention resides in the claims hereinafter appended.

Claims: Use of a sprayable strongly acidic cleaner composition, formulated to reduce the formation of a choking aerosol when sprayed, the composition comprising: (a) a strong acid; (b) an organic surfactant; (c) an organic polymer thickener; (d) water, wherein said composition is thixotropic, producing an aerosol having a mean airborne aerosol particle size of greater than 200 µm by spraying. Use according to claim 1, wherein the strong acid comprises a strong mineral acid. Use according to claim 2, wherein the acid comprises phosphoric acid. Use according to claim 2 or 3, wherein the acid comprises a mixture of a mineral acid and an organic acid selected from the group consisting of acetic acid, citric acid, sulfamic acid, maleic acid, fumaric acid, benzoic acid and mixtures thereof. Use according to claims 2-4, wherein the composition comprises 1 to 20 wt.% of a strong acid. Use according to any of the claims 2-5, wherein the organic surfactant comprises a nonionic surfactant. Use according to any of the claims 2-5, wherein the organic surfactant comprises a cationic surfactant. Use according to claims 4-5, wherein the organic surfactant comprises a combination of a polyalkylene oxide nonionic surfactant and an alkyl dimethyl amine oxide cationic surfactant. Use according to any of the claims 2-5, wherein the organic surfactant comprises an amphoteric surfactant Use according to any of the claims 6-8, wherein the composition comprises 1 to 20 wt.% of an organic surfactant. Use according to any of the claims 2-10, wherein the composition comprises 0.01 to 10 wt.% of a polyvinyl alcohol thickener composition. Use according to claim 11, wherein the polyvinyl alcohol composition has a molecular weight greater than 20,000. Use according to claim 11 or 12, wherein the polyvinyl alcohol composition has a degree of hydrolysis of greater than 87%. Use according to any of the claims 2-13, wherein the composition additionally comprises a compatible solvent. Use according to claim 14, wherein the composition comprises 0.1 to 10 wt.% of an hydroxy substituted organic solvent composition. Use according to claim 15, wherein the hydroxy substituted organic solvent comprises methanol, ethanol, propanol, isopropanol, ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, propylene glycol methyl ether, dipropylene glycol methyl ether, ethylene glycol methyl ether and mixtures thereof.

Inventors: BONA GREGORY T, KELLER CYNTIA A, LENTSCH STEVEN E, MAN VICTORIA F, BONA, GREGORY T., KELLER, CYNTIA A., LENTSCH, STEVEN E., MAN, VICTORIA F.
Applicants: ECOLAB INC, ECOLAB, INC.
Application year: 1994
Main classification: C11D17
IPC codes: C11D1, C11D17, C11D3